AMTI Products
Getting a Critical Packing Machine Online After a Facility Move

Industry: Manufacturing / Packaging

Location: Illinois

Challenge: New facility had 208V service; one critical packing machine required 220V to operate

Solution: Buck/boost transformer to step up 208V to 220V for the packing machine

The Challenge: New Building, Wrong Voltage for One Critical Machine

AMTI Products was growing. The company had outgrown their existing facility and was moving to a larger building to support expanded operations. It's the kind of move that signals success: more space, more capacity, more room to scale.

But when the electrical team assessed the new location, they found a common and frustrating problem: the available voltage didn't match one of their most important pieces of equipment.

The previous facility had provided 220V power. The new building's utility service delivered 208V. For most of AMTI's equipment, this wasn't an issue. Many machines are designed to operate across a voltage range and could handle 208V without any problems.

But one machine couldn't: a packing machine that was critical to AMTI's production line. This unit required 220V to function correctly, and it had no tolerance for running at a lower voltage. Without that machine, AMTI's packing operation, and by extension their ability to ship finished products, would be stalled.

The company had a new building, a growing business, and a production line that couldn't fully come online because of a 12-volt gap.

Why 208V Wasn't Close Enough

The difference between 208V and 220V is roughly 6%. That sounds small. For some equipment, it is small enough to tolerate. But for machinery with motors and controls designed specifically for 220V, running at 208V introduces real problems:

• Reduced motor performance: Motors produce less torque at lower voltage, meaning the packing machine couldn't operate at its rated speed and force

• Increased current draw: The motor pulls more amperage to compensate, generating excess heat

• Overheating risk: Chronic undervoltage causes motors to run hotter, accelerating insulation breakdown and bearing wear

• Potential control issues: Some machine controls and sensors are voltage-sensitive and may malfunction or refuse to start at incorrect voltage

• Warranty concerns: Operating equipment outside its rated voltage range typically voids the manufacturer's warranty

For a machine that the entire packing line depends on, "close enough" wasn't acceptable. AMTI needed 220V exactly.

The Solution: A Buck/Boost Transformer

The fix was straightforward: a buck/boost transformer installed between the facility's 208V power supply and the packing machine.

Buck/boost transformers are compact autotransformers designed to make small, precise voltage adjustments. In AMTI's case, the transformer was configured to boost the incoming 208V up to the 220V the packing machine required.

The installation was simple and targeted. The buck/boost transformer served only the packing machine. Every other piece of equipment in the facility continued running on 208V without any changes. There was no need to modify the building's electrical service, negotiate with the utility, or rewire the facility.

Why Buck/Boost Transformer Was the Right Solution

• Speed. AMTI was in the middle of a facility move. Every day the packing machine sat idle was a day products weren't shipping. A buck/boost transformer could be sourced and installed quickly, getting the line back up in days, not weeks.

• Precision. The 208V-to-220V boost is a standard application for buck/boost transformers. The output voltage is stable and consistent, giving the packing machine exactly what it needs.

• Cost. Because buck/boost transformers only transform the voltage difference (not the full load), they are significantly smaller and less expensive than full isolation transformers. For a single machine that needed a small voltage correction, this was the most economical path.

• Zero disruption. The rest of AMTI's equipment ran fine on 208V. The buck/boost transformer was installed specifically for the packing machine, leaving every other circuit in the building untouched.

• Permanent installation. Buck/boost transformers are approved by NEC handbook for this application and designed for permanent use. Once installed, it became part of the facility's electrical system. No ongoing adjustments, no temporary workarounds.

The Results

With the buck/boost transformer in place, AMTI's packing machine came online at the correct voltage. The full production line was operational in the new facility.

• The packing machine ran at 220V as required full performance, correct speed, no overheating

• Production resumed on schedule the facility move didn't create extended downtime

• No changes to the building's electrical service the 208V utility supply remained as-is

• All other equipment continued operating normally only the packing machine needed correction

• The solution was permanent and maintenance-free installed once, working continuously

What could have been a weeks-long delay involving utility coordination or expensive rewiring was solved with a single, targeted transformer installation.

Why Facility Moves Create Voltage Problems

When businesses relocate, voltage mismatches are one of the most common electrical surprises. They happen because:

1. Utility voltage isn't the same everywhere. Different service areas, different buildings, and different utility companies may provide different standard voltages. 208V and 220V are both common. But they're not interchangeable for all equipment.

2. Equipment accumulates over years. Companies buy machines based on available voltage at their current location. When they move, the new location may not match.

3. Most equipment handles the difference...but not all. Many modern machines are rated for a range (like 208-240V). But some equipment, especially older or specialized machinery, requires a specific voltage.

4. The mismatch is usually small. The gap between 208V and 220V, or 208V and 240V, is exactly the kind of minor correction buck/boost transformers are designed to handle.
   

For growing businesses like AMTI, the goal during a facility move is to get fully operational as quickly as possible. Buck/boost transformers turn a potential weeks-long electrical problem into a same-week solution.

Frequently Asked Questions

What is a buck/boost transformer?

A buck/boost transformer is a small, efficient transformer that raises (boosts) or lowers (bucks) voltage by a small amount. It is the standard solution for correcting minor voltage differences between a building's power supply and the requirements of specific equipment.

Can a buck/boost transformer convert 208V to 220V?

Yes. Boosting 208V to 220V is a common and straightforward application for buck/boost transformers. The approximately 6% voltage increase is well within the standard operating range of these units.

Why didn't the other equipment need correction?

Most of AMTI's equipment was designed to operate across a voltage range, meaning it could accept both 208V and 220V without issue. Only the packing machine required exactly 220V, making it the only piece of equipment that needed a buck/boost transformer.

How long does installation take?

A qualified electrician can typically install a buck/boost transformer in a few hours. The unit is wired between the power source and the equipment it serves. No facility-wide changes are required.

Is a buck/boost transformer a permanent solution?

Yes. Buck/boost transformers are UL-listed for permanent installation. They are standard electrical equipment that operates continuously without ongoing maintenance or adjustment.

Could AMTI have asked the utility to provide 220V?

Changing utility service voltage is typically expensive, time-consuming, and sometimes not possible depending on the utility's infrastructure. The typical solution to change voltage across the building is install a transformer at the service entrance. A buck/boost transformer solves the same problem faster and at a fraction of the cost.

Key Takeaways

• Facility moves frequently reveal voltage mismatches between a building's power supply and existing equipment requirements

• Even small voltage differences matter a 12-volt gap between 208V and 220V can prevent critical equipment from operating correctly

• Buck/boost transformers provide targeted, fast, and permanent correction solving the problem for specific equipment without changing the building's electrical service

• Most equipment tolerates voltage ranges, but some doesn't the machines that require exact voltage are the ones that need buck/boost transformers

• Speed matters during a move buck/boost transformers get equipment online in days, not weeks

Buck/boost transformers are a proven solution for voltage correction during facility moves, expansions, and equipment upgrades. To learn more about solving voltage mismatch challenges, contact Sanzo Sales.